Safety Rules Pressure Vesel

STATIC & MOBILE PRESSURE VESSEL (UNFIRED) RULES, 1981. Introduction

The SMPV(U) Rules, 1981 regulate, possession and transport of compressed gases, valves, safety fittings used in pressure vessels containing compressed gases viz., permanent gas, liquefiable gases.

Licensed Premises

Approved Premises

Feed back

Under the SMPV(U) Rules,1981, different type of licences and different types of approvals are granted. The licence is required for possession of static pressure vessels and for transport of pressure vessels (Mobile tankers) containing compressed gases. Approvals are granted for fabrication of pressure vessels, manufacture of safety fittings for pressure vessels, recognition of third party inspecting agency/competent persons, repair/modification or import of pressure vessels.

THE STATIC & MOBILE PRESSURE VESSELS (UNFIRED) RULES, 1981 INTRODUCTION 8.1

OBJECTIVE, DEFINITION, ENFORCEMENT, EXEMPTION ETC., IN THE SMPV(U) RULES, 1981.

(a)

OBJECTIVE : Compressed gases filled in metallic container pose potential hazard and the container explodes. Hence, the Govt. of India vide Notification No.M-1272(1) dated 28/09/1938 has declared compressed gas filled in a metallic container to be deemed to be an explosive under Section 17 of the Explosives Act, 1884. Subsequently, in exercise of powers vested in Section V & VII of the Act, the Govt. framed the Static & Mobile Pressure Vessels Rules, 1981 to regulate filling, possession, transport and import of compressed gases in pressure vessels.

(b)

DEFINITIONS : In these rules, unless the context otherwise requires, --

(a) “Act” means the Indian Explosives Act, 1884 (4 of 1884); (b) “approved” means a drawing, design, specification or code approved by the Chief Controller ; (bb) “bottling plant” means a premises where cylinders are filled with compressed gas”

(c) “Chief Controller” means the Chief Controller of Explosives; (d) “Competent person” means a person or an organisation recognised by the Chief Controller, for such gases and for such period as may be specified as competent for carrying out tests, examination, inspections and certification for installations and transport vehicles as stipulated in these rules, if such a person or organization possesses the qualifications, experience and other requirements as set out in Appendix II to these rules and is recognized as per procedure laid down in rule 11-A: Provided that the Chief Controller may relax the retirements of qualifications in respect of a competent person if such a person is exceptionally experienced and knowledgeable but not the requirements in respect of the facilities at his command;

(e) “Compressed Gas” means any permanent gas, liquefiable gas or gas dissolved in liquid, under pressure or gas mixture which in a closed pressure vessel exercise a pressure exceeding two atmosphere (gauge) at the maximum working temperature and includes Hydrogen Fluoride. In case of vessel without insulation or refrigeration, the maximum working temperature shall be considered as 550 C.;

(f) “Controller of Explosives” includes Jt. Chief Controller of Explosives, the Deputy Chief Controller of Explosives, Deputy Controller of Explosives and Assistant Controller of Explosives;

(g) “corrosion” means all forms of wastage, and includes oxidation, scaling, mechanical abrasion and corrosion;

(gg) “critical temperature” means the temperature above which gas cannot be liquefied by the application of pressure alone,” (ggg) “cylinder” or “gas cylinder” means any closed metal container intended for storage and transport of compressed gas having the same meaning as assigned to it in clause (xvi) of rule 2 of the Gas Cylinder Rules, 1981,”

(h) “design” includes drawings, calculations, specifications, models codes and all other details necessary for the complete description of the pressure vessel and its construction;

(i) “design pressure” means the pressure used in the design calculations of a vessel for the purpose of determining the minimum thickness of the various component parts of the vessels ;

(ii) “dispenser” means an equipment installed in liquefied petroleum gas dispensing station, meant for dispensing liquefied petroleum gas as automotive fuel to motor vehicles,” (j) “district authority” means— (i) in towns having a Commissioner of Police, the Commissioner or a Deputy Commissioner of Police; and (ii) in any other place, the District Magistrate;

(k) “filling density” means the ration of weight of liquifiable gas allowed in a pressure vessel to the weight of water that the vessel will hold at 150 C;

(kk) “fill point” means the point of the inlet pipe connection of a vessel where hose is connected for filling the compressed gas into the vessel,” (l) “flammability range” means the difference between the minimum and maximum percentage by volume of the gas in mixture with air that forms a flammable mixture at atmospheric pressure and ambient temperature’

(m) “flammable compressed gas” means gas 13 percent or less of which when mixed with air forms a flammable mixture or whose flammable range with air is greater than 12 percent;

(n) “Form” means the Form appended to these rules; (o) “gas free” in relation to a pressure vessel means the concentration of flammable or toxic gases or both if such pressure vessel is within the safe limits specified for persons to enter and carry out hot work in such vessels;

(p) “Inspector” means a professional organization recognized by the Chief Controller for certifying pressure vessels and their fittings after carrying out stage wise inspection during fabrication as stipulated in the rules so as to ensure that the pressure vessels are designed and constructed in accordance with IS:2825 or any other Code approved by the Chief Controller, if the constituent members of the organization possesses the qualifications and experience and other requirements as set out in Appendix II to these rules and the recognition is granted as per procedure laid in rule 11A;

(q) “installation” means any place which has been specially prepared for the storage of compressed gas in pressure vessels;

(r) “liquefiable gas” means any gas that may be liquefied by pressure above -100 C, but will be completely vaporized when in equilibrium with normal atmospheric pressure (760 mm Hg) at 300 C;

(ra) “liquefied petroleum gas” included hydrocarbon gases in liquefied state at normal ambient temperature by the application of pressure, and conforming to the Indian Standard Specification No.: IS:4576,” (rb) “liquefied petroleum gas dispensing station” means a premises used for storing and dispensing liquefied petroleum gas as automotive fuel to the motor vehicles,” (rc) “motor vehicle”, means a vehicle having the meaning assigned to it in sub-section (28) of section 2 of the Motor Vehicle Act 1988 (59 of 1988),” (rd) “petroleum service station”, means a premises used for storage of petroleum for the purpose of fuelling motor vehicles, and licenced in Form – XII of the Petroleum Rules, 1976,”

(s) “permanent gas” means a gas whose critical temperature is lower than -100 C; (t) “Pressure vessel” means any closed metal container of whatever shape, intended for the storage and transport of any compressed gas which is subjected to internal pressure and whose water capacity exceeds one thousand liters and includes inter connecting parts and components thereof upto the first point of connection to the connected piping and fittings, but does not include containers wherein steam or other vapour is or is intended to be generated or water or other liquid is or is intended to be heated by the application of fire or the products of combustion or by electrical means, heat exchangers, evaporators, air receivers, steam type digestors, steam type sterilizers, autoclaves, reactors, calorifiers, pressure piping components such as separators or strainers and vessels containing a liquid under a blanket of compressed inert gas;

(u) “safety relief device” means an automatic pressure relieving device actuated by the pressure upstream of the valve and characterized by fully opened pop action, intended to prevent the rupture of a pressure vessel under certain conditions of exposure ;

(v) “source of ignition” means naked lights, fires, exposed incandescent materials, electric welding arcs, lamps, other than those specially approved for use in flammable atmosphere, or a spark or flame produced by any means;

(vv) “ tank truck loading or unloading gantry” or “hard stand” means the position of parking of tank truck or mobile pressure vessel for loading or unloading of compressed gas into or from it,” (w) “transport” means the transport of a pressure vessels filled with any compressed gas from one place to another but does not include movement of the vessel from one place to another in the same premises;

(x) “vehicle” means a mechanically propelled carriage designed to transport by land compressed gas in a pressure vessel mounted thereon, and shall not include a vessel forming the barrel of a rail tank wagon;

(y) “vessel” means a pressure vessel; (z) “water capacity” means capacity in litres of the pressure vessel when completely filled with water at 150 C.

(c)

ENFORCEMENT : Under the SMPV(U) Rules, the following enforcement are provided :1) Manufacture of pressure vessels and their fittings. 2) Storage of compressed gas in pressure vessels. 3) Transport of compressed gas in pressure vessels. 4) Periodic testing of pressure vessels and fittings. 5) Modification/repairs of pressure vessels. 6) Recognition of inspectors and competent persons. 7) Enquiry into accident. 8) Permission for import of pressure vessels. Authority in enforcement is Chief Controller of Explosives or any other officer authorized by him. The District Authority is required to take penal action for infringement of rules reported to him by Chief Controller of Explosives.

(d)

EXEMPTIONS : Under rule 3, process vessel forming plant of the process plant are exempted provided the process gas is produced and consumed in the same process plant and the holding capacity of the vessel does not exceed 16 hrs. of consumption in the process plant at designated flow rate. Armed forces and Defence Establishments are exempted under Section 14 (1)(a) of the Act.

8.2 (A)

FORM OF LICENCES, PURPOSE AND AUTHORITY

Form of licences Form III

Form IV

Form V

Purpose Storage of compressed gas in pressure vessels in an installation. Transport of compressed gas in Mobile pressure vessels mounted on vehicle Storage of LPG in Auto-LPG dispensing station for filling

Authority Chief Controller of Explosives

Chief Controller of Explosives

Chief Controller of Explosives

motor vehicles

(B)

Other approvals/recognition (not requiring licence)

Purpose Approval of shops for manufacture of pressure vessels and fittings Approval of design of pressure vessels/fittings Permission for import of pressure vessels and approval of their design Approval of procedure and design for repairs/modifications of pressure vessels Recognition of Inspectors

Authority Chief Controller of Explosives Chief Controller of Explosives Chief Controller of Explosives Chief Controller of Explosives Chief Controller of Explosives

PROCEDURE ADOPTED FOR GRANT/RENEWAL/ AMENDMENT ETC., OF VARIOUS TYPES OF LICENCES UNDER SMPV(U)RULES, 1981 For filling of compressed gas in any pressure vessel and storage/transportation of compressed gas contained in a pressure vessel the licence under these rules is obligatory (rule IV), except the exemptions given for process as per rule 3. No person shall deliver or dispatch any compressed gas filled in a pressure vessel to any person other than the holder of a licence issued under the rules. Pressure vessels used for storage/transportation of compressed gas shall be of a design approved in writing by Chief Controller of Explosives and shall be fabricated by an approved manufacturer under inspection of third party inspection agency [procedures for approval of shop, approval of design etc. as prescribed in Para 8.3 ]. Maximum quantity of liquefiable gas filled into any pressure vessels is limited to 95% of the total water capacity considering density of the gas at 550 C. in case of refrigerated or insulated vessel, the maximum filling capacity will be 95% at the operating temperature considering the density of the gas at the operating temperature. In case of permanent gases the operating pressure shall not exceed the design pressure. Each pressure vessel shall have a metal plate permanently fixed showing the following particulars :-

1) 2) 3) 4) 5) 6) 7) 8) 9)

Manufacturers name and identification mark. Standard/code to which vessel is constructed. Official stamp of the inspector. Design pressure. Date of initial hydrotest and subsequent tests. Hydrotest pressure. Water capacity in litres. Gas capacity (for liquefiable gases). Name or chemical symbol of the gas for which the vessel is to be used.

Each vessel is to be fitted with at least two independent safety valves whose set pressure shall not exceed 110% of the design pressure, pressure gauge, drain, content gauge, temperature gauge and shut-off valves. In case of flammable or toxic gases of liquid (more than 3mm. dia ) and vapour (8mm. dia) connections except relief valves and drains shall have emergency shut-off valves, such as excess flow valve or automatic /remotely operated control valve (refer rule 18). Pressure vessel shall be installed on a proper design foundation taking into consideration static loading, test loading, mean loading & operational loading (refer rule 23). INQUIRY INTO ACCIDENT : In case of any accident involving any pressure either static or mobile, the licensee is required to intimate Chief Controller of Explosives and the nearest Police Station immediately. The Chief Controller of Explosives nominates an officer to investigate into the cause of the accident and submit his technical report. In case of serious accident, the inquiry is to be conducted by District Authority or Central or State Government. As per Section 9 & 9(a) of the Act, in such inquiries a departmental officer is nominated to assist the inquiry committee in technical matters. Further action regarding prosecution/suspension/cancellation of the licence is taken based on the findings and violations as per the report.

Question ? 1. Was it useful in your work activities connected to this department? 2. Are you a frequent visitor to this manual site?

3. Are you a frequent visitor to the offices of this department. 4. What are your specific suggestion to improve it? Give suggestions with reasons. 5. Has this chapter helped you in filing/making proper documents or will your think that you may still face difficulty in filling/making proper forms and documents after reading this chapter? 6. Do you have specific suggestions to make it more user friendly? 7. Do you think of unnecessary element in this chapter which can be avoided/deleted ? 8. Do you have any suggestion (s) for change in Legislation ? Give details with reasons. 9. Give brief details of your organization/yourself through the suggestion form which can be had by clicking the feedback button.

HOME

Storage in static vessels

Transportation in tankers

LICENSED PREMISES UNDER STATIC & MOBILE PRESSURE VESSELS (UNFIRED) RULES, 1981. Under the SMPV(U) Rules, 1981, different types of licenses are granted for different purposes. The license for storage in static vessels is granted in Form III.

Auto LPG dispensing station

The license in form IV is granted for transportation of compressed gas in mobile tankers. The license for auto LPG dispensing station is granted in Form V.

Feed back

FORM III TO STORE COMPRESSED GAS IN PRESSURE VESSELS IN AN INSTALLATION Applicants Action Any person desiring to install pressure vessel for storing compressed gas is required to obtain a prior approval from Chief Controller of Explosives by submitting following documents. 1) 2) 3)

4)

Scrutiny fee of Rs 100/Brief description of the proposal/project. Site Plan : 4 copies of the site plan showing the location of the proposed installation and facilities and other protected works within 100 mtrs. on all sides. In case of large installation of LPG exceeding 100 MT, the facilities such as roads, buildings, Survey No. etc. within 500 mtr. from all sides should be indicated. Layout plan : 4 copies showing details of layout, foundation, installation of pressure vessel, name of the gas, pump compressor house, tank truck loading/unloading area, route of pipelines, brief specification of pressure vessels and pipelines and electrical fittings.

NOTE :1)

2)

3)

In case of flammable gases, the vessels and handling areas should be protected with water sprinklers and sufficient number of fire hydrants/monitors connected to an independent fire water tank should be provided and shown. In case of LPG bottling plants/LPG terminals having more than 100 MT. Bulk storage, the fire water reserve should be sufficient for 4 hrs. of fire fighting and the fire fighting should meet the requirements of OISD:144; for small bottling plants not exceeding 100 MT. LPG storage, the fire water tank should be sufficient for 2 hrs. fire fighting and the requirements of OISD-169 be met. In case of smaller consumer installations, the fire water capacity should be adequate to the satisfaction of Chief Controller of Explosives. In case of toxic gases adequate facilities for absorption/neutralization of the gas in case of leakage depending on the nature of gas should be provided. In addition

4)

personnel protected equipment like gas masks, breathing apparatus etc., as applicable should also be provided. The pressure vessels should be installed in the installation only of above ground. However, the corrosive/toxic gases like chlorine and ethylene oxide and toxic non flammable gases like liquid oxygen, carbon-di-oxide etc. where shed roof and side walls are being also allowed. Installation of LPG vessels are also allowed to be installed under ground or under mound (covered with earthen mound). Mounded installation of LPG vessels should be designed for external load differential settlement and shall be installed under minimum 500 mm. earthen tower. Arrangements for prevention of seepage of water should be provided. The foundation can be either RCC for small tanks or compacted sand bed for larger tanks. The nozzles of the vessel should be above the mound preferably through a nozzle box. If submersible pump is not provided and the outlet is from bottom, the bottom outlet pipe should be taken 3 mtr. outside the vessel through RCC inspection tonnel of the returning wall. In case of the under ground vessels also should be similarly designed for external pressure and other stresses and installed in a mesentery pit keeping the minimum distance of 1 mtr. between vessel and the pit and the pit should be filled with soil/sand upto 500 mm. above the top level of the vessel. Both mounded and under ground vessel shall be coated with at least 300 microns. DFT epoxy folder/anti corrosive coating applied by airless gun and holiday tested to check the quality of coating. In addition cathodic protection also should be provided. In case of smaller vessels, sacrificial anode type cathodic protection is adequate. For larger vessel impressed current type cathodic protection is required.

5)

Minimum clear distances from the vessel and other facility for various types of gases are given below :-

TABLE 1 Minimum safety distances for corrosive, toxic and permanent flammable gases

Sl. Nos

(i) (ii) (iii) (iv) (v)

Water capacity of vessel(in litres)

Not above 2000 Above 2000 but not above 10,000 Above 10,000 but not above 20,000 Above 20,000 but not above 40,000 Above 40,000

Minimum distance from building Minimum or group of buildings or line of distance between adjoining property pressure vessels 5 meters 1 meter 10 meters 1 meter 15 meters

1.5 meters

20 meters

2 meters

30 meters

2 meters

TABLE-2 Minimum safety distances for non-corrosive, non-flammable or non-toxic gases Seri al No. i) ii) iii) iv) v)

Seria l No.

Water Capacity of vessel Minimum distance from Minimum distance (in litres) building or group of between vessels buildings or line of adjoining property Not above 2000 3 meters 1 meter Above 2000 but not above 5 meters 1 meter 10,000 Above 10,000 but not above 7.5 meters 1.5 meters 20,000 Above 20,000 but not above 10 meters 2 meters 40,000 Above 40,000 15 meters 2 meters TABLE - 3 Minimum safety distances for liquefied flammable gases. Water Capacity Minimum distance from line of Minimum distance of vessel (in litres) adjoining property or group of between vessels buildings not associated with storage & operation. Aboveground underground or Abovegroun undergro vessel aboveground d vessel und or vessels covered abovegro with und earth(mound) vessels covered

i) ii) iii) iv) v) vi)

vii) Viii

ix)

x)

5 meters 10 meters

3 meters 3 meters

1 meter 1 meter

with earth mound) 1 meter 1 meter

10 meters

5 meters

1 meter

1 meter

15 meters

7.5 meters

1.5 meters

1 meter

20 meters

10 meters

2 meters

1 meter

30 meters

15 meters

1 meter

Above 3,50,000 but 40 meters not above 4,50,000 Above 4,50,000 but 60 meters not above 7,50,000

15 meters

Above 7,50,000 but 90 meters not above 38,00,000 above 38,00,000 120meters

15 meters

2 meters or ¼th of the sum of diameter of adjacent vessel or ½ the diameter of the two adjacent vessels whichever is greater.

Not above 2000 Above 2000 but not above 7500 Above 7500 but not above 10,000 Above 10,000 but not above 20,000 Above 20,000 but not above 40,000 Above 40,000 but not above 3,50,000

15 meters

15 meters

1 meter 1 meter

1 meter

1 meter

TABLE – 4 Minimum Safety distances (in meters) between facilities associated with storage of liquefied flammable gas in petroleum refinery, gas processing plants, storage terminals and bottling plants. (A) FOR TOTAL STORAGE ABOVE 100 TONNES Fire Water Pump room

Sheds for Tank Truck Tank Wago loading/ filling n unloading storage, gantr gantry evacuation y of cylinders

Pump/ compr essor Shed

Storage Vessel

30

30

50

15

60

Property buildings associated storage operation Sheds for filling storage, evacuation of cylinders Tank Truck loading/ unloading gantry Tank Wagon gantry Pump/compressor Shed Fire Water Pump room

30

30

50

30

--

From/To

Storage Property Vessel line/ buildings not associated with storage and operation

Table - Table - 3 3 line/ Table - ----not 3 with and 30

30

15

30

50

15

60

30

30

30

30

50

30

60

50

50

50

50

50

30

60

15

30

15

30

30

---

60

60

---

60

60

60

60

---

(B)

FOR TOTAL STORAGE NOT ABOVE 100 TONNES Property line/ buildings not associated with storage and operation Table 3 -----

Sheds for filling storage, evacuation of cylinders

Tank truck unloading/ loading gantry

Fire Water Pump room

Table - 3 15

15 15

30 --

Table 3

15

15

15

30

15

15

15

15

30

30

--

30

30

--

From/To

Storage Vessel

Storage Vessel Property line/buildings not associated with storage & operation Sheds for filling storage, evacuation of cylinders Tank truck unloading/loading gantry Fire Water Pump room

Table-3 Table-3

DEPARTMENTAL ACTION : On scrutiny and examination of the documents, approval is granted if the documents are in order meeting the requirements of the rules. If not, the matter is pointed out to the applicant. In case of large bottling plants/terminals/toxic gas installations, Chief Controller of Explosives may call for additional documents like risk analysis report, safety management report or he will call for technical team of the applicant for discussions to clarify related issues. B)

GRANT OF LICENCE : After completion of the installation as per approved plan, the applicant is to submit to Chief Controller of Explosives the following documents :1) 2) 3)

Application in form I. 4 copies of site layout and fabrication drawing for each tank and other drawings as built. 3 copies of safety certificates for the entire installation from a recognized competent person under rule 33.

4)

5)

3 copies of test & inspection certificate (control certificate) from a inspector/inspecting agency under whose supervision the pressure vessels were manufactured. NOC from the District Magistrate (other than non-toxic/non flammable gases). Licence fee by way of Bank Draft calculated as below :Rs.1000/- for first 5000 litres

Rs. 500/- for every additional 1000 litres of the water capacity of the vessel/fabricated vessel subject to a maximum of Rs.10,000/- per year. Licence can be granted for a maximum 3 years period. DEPARTMENTAL ACTION : The documents if found in order licence in form III is granted and sent to the Circle/ Sub-circle office having jurisdiction for inspection of the facilities. If on inspection the facilities are found in order, the inspecting officer endorses the licence and sends to the licensee. In case of minor deviations he points it out to the licensee and on receipt of compliance further action of endorsement of licence is taken. In case major deviations, the matter is referred back to the Chief Controller of Explosives for further action as desired fit. In case deviations are of such nature which endangers safety and which cannot be complied by the licensee, the licence is revoked. C)

PRIOR APPROVAL FOR ADDITION/ALTERATIONS : If a licensee desires to make any alterations in the premises prior approval from Chief Controller of Explosives is required for his proposal describing the proposed additions/alterations, necessary drawings showing the additions/alterations and scrutiny fee of Rs.50/- to be submitted to the Chief Controller of Explosives.

DEPARTMENTAL ACTION : If the proposal for additions/alterations meets the requirements of the rules, approval is granted. In case any discrepancy or deviation, the matter is pointed out to the applicant. D)

AMENDMENT OF LICENCE :

After completion of the additions/alterations, the licensee should submit to Chief Controller of Explosives the following documents for amendment of the licence. 1) 2)

Application in form I. 4 copies of as built drawings showing the additions/alterations carried out.

3) 4) 5) 6)

4 copies of fabrication drawings of the new tank (if added). 3 copies of safety certificate from a competent person under rule 33. 3 copies of the test & inspection certificate for the vessels if provided from the inspector. A Bank Draft of Rs.10/- as amendment fee with additional licence fee, if any.

NOTE : 1)

If the amendment is not in respect of any additions/alterations, but for change of product from one gas to another gas, change in company’s name it will not involve submission of safety certificates and tank inspection certificate. In such cases only relevant documents like certification of the registration of the Company, is to be submitted.

2)

If, however, change in company’s name is not due to restructuring or renewing of the same company, but involve transfer of the property from one company to another company, it will not be a case of amendment and in such case the new company will have to obtain a fresh licence in his name.

INSPECTION : The licensed premises is compulsorily inspected by the field officer of the department at the time of initial grant of licence as mentioned above. Subsequently, the premises are periodically inspected. Check points for inspection :i) ii) iii)

iv)

v) vi) vii)

viii)

Whether name of the company appearing in the licence is in actual possession of the installation. Whether location of the installation and the surrounding facilities tallies with those shown in the site plan. Whether the layout of the various equipments like pressure vessels, pump compressors, fire hydrants, fencing and the various distances at the site tallies with those shown in the approved layout plan (actual distances are to be measured). Whether the description of pressures vessels, their serial no., name of gas, water capacity, design pressure, test pressure, test date, fittings, match with the inspection and safety certificates and application drawings. Whether the layout of pipelines, are as per the approved drawings. Whether the pipelines and other fittings are suitable for the compressed gas at the intended operating pressure and temperature. Whether corrosion prevention arrangement of the vessels, pipelines etc. are provided (anti corrosive coating or cathodic protection as the case may be). Whether tank truck decantation facility as per layout plan is provided.

ix)

x) xi) xii) xiii)

xiv)

xv) xvi)

Whether the vessels, pipeline joints and the tank truck unloading area for flammable gases is provided with earthing/bonding. The reeling resistance may also be verified. Whether different colour codes have been adopted for liquid and vapour lines and the valves have different pipes are marked. Whether the internal layout within the installation is suitable for tank truck If the safety valves, excess flow valves and remotely operated valves are actually provided as per safety certificate. Whether the hoses used for unloading/loading are of suitable specification for the product and whether arrangement for periodic inspection and testing of hoses is available. Whether the fire protection system like sprinklers, hydrants,. Monitors, water storage, fire water pumps etc. are provided as per the approved plan/certificate. Whether their layout and capacities are adequate. Whether other safety equipments like gas marks, breathing apparatus, eye wash shower etc. for any particular toxic/corrosive gas are provided. Whether qualified and experienced technical manpower is available for safe operations of the facilities and for handling emergency situations.

Question ? 1. Was it useful in your work activities connected to this department? 2. Are you a frequent visitor to this manual site? 3. Are you a frequent visitor to the offices of this department. 4. What are your specific suggestion to improve it? Give suggestions with reasons. 5. Has this chapter helped you in filing/making proper documents or will your think that you may still face difficulty in filling/making proper forms and documents after reading this chapter? 6. Do you have specific suggestions to make it more user friendly? 7. Do you think of unnecessary element in this chapter which can be avoided/deleted ? 8. Do you have any suggestion (s) for change in Legislation ? Give details with reasons. 9. Give brief details of your organization/yourself through the suggestion form which can be had by clicking the feedback button.

MODEL DRAWING

FORM IV UNDER SMPV(U) RULES 1981 Purpose : The licence in form IV is granted to transport compressed gases in pressure vessels on land by mechanically propelled vehicle. Such vehicle for transportation of compressed gases is called road tanker or in short, tanker. Note:-

1. For definition of pressure vessels or in short, vessels:- See item (t) of Rule 2 of SMPV(U) Rule 1981 2. For transportation purposes, the vehicle used may be fixed chassis or trailer chassis, depending on the quantity of compressed gas, to be transported. All chassis and the maximum allowed quantity of compressed gas for that particular vehicle are approved by Chief Controller of Explosives, Nagpur:a. Maximum quantity permissible for transport of compressed gas (flammable) 18 MT with GVW of 35.2 MT b. Maximum quantity permissible for transport of compressed gas (toxic) 15 MT with GVW of 35.2 MT All these requirements, load distribution etc. must also conform to the relevant section of Motor Vehicle Act as per Ministry of Surface Transport. 3. All the vessels which are mounted on chassis should be must be fabricated as per design code like IS-2825, ASME Sec. VIII Div. 1 BS:5500 and any other code as approved by the Chief Controller of Explosives, Nagpur (Rule 12 of SMPV(U) Rules 1981). The Chief Controller of Explosives, Nagpur has given approval to the various fabricators for fabrication of pressure vessel. So all vessels must be fabricated by fabricators approved by Chief Controller of Explosives, Nagpur as per terms and conditions laid down in the above said code or by the Chief Controller of Explosives i.e. by stage-wise inspections by third party, competent persons etc. Therefore prior approval for mountig of a pressure vessel of particular make and model of vessel is also to be approved in advance For transport, additional factor due to

acceleration/deceleration equal to 3g (pay load x 3/cross sectional area of the vessel). Additional factor should be taken while computing the design pressure. The vessel made of carbon steel meant for transportation of compressed gas should also be stress relieved

4. Fittings – Each vessel shall be provided with each of the following fittings all of which should be suitable for use with the gas at pressures not less than the design pressure of the vessel to which they are fitted and for temperatures appropriate to the characteristics of the gas and operating conditions, namely :i. ii. iii. iv. v.

Pressure relief valve connected to the vapour space; Drains; Contents gauge or maximum level indicator; Pressure gauge connected to the vapour space; Means of measuring the temperature of the contents of the vessel.

Note : For details refer Rule 18(2) under SMPV(U) Rules, 1981. Licensing Authority : Respective circle office of the Department of Explosives under whose jurisdiction the applicant belongs. The licence in respect of CO2 and Cryogenic vessel is granted by Chief Controller of Explosives, Nagpur. Procedure:

Grant of licence :Various on-line steps adopted for grant of licence in form IV are as under: ? ? Submission of drawings and the other required documents by the applicant to the licensing authority for grant of licence.

? ? Grant of licence by the licensing authority.

Note :-

1. The

licence fee for one year is Rs.1000/- (fixed) irrespective of the licensed capacity as per schedule attached to SMPV[U] Rules.

The detailed step by step procedure are as under:

Submission of documents by applicant for grant of licence (Applicants Action) : Applicant must submit the following documents to the licensing authority for grant of licence: ? ? Bank draft of Rs . as licence fee/scrutiny fee. The B/D should be drawn on any nationalised bank, in favour of Jt. CCE/appropriate authority and should be payable at appropriate place as applicable for the concerned licensing authority. The Bank Draft should have at least 2 months validity from the date of submission of application for grant of licence. ? ? Application form II duly filled in and signed by the applicant/ authorised employee (in case of company). Typed copy of form II (given in the SMPV(U) Rules, 1981) is acceptable. Please note that no column of the form should be left blank. Inapplicable columns should be filled as NA i.e., not applicable. Full postal address with pin code should be written. No overwriting or major corrections will be accepted. Minor correction should be initialed. ? ? Certificate from the approved fabricator that the tanker has been fabricated by him required in case of new tanker. ? ? Weighment slip for the actual unladen weight of the vehicle. ? ? No objection letter from the previous owner and undertaking (if required) in case of change of ownership. ? ? Original licence with approved drawing granted to the erstwhile owner in case of change of ownership ? ? Attested copy of the RC book under Motor Vehicle Rules, showing name and address of owner, laden weight, un-laden weight etc. ? ? Specimen signature of the applicant. ? ? Four copies of fabrication and mounting drawings of the vessel (blue print or computerized one without hand correction), each signed by the competent person or the fabricator as applicable. Each copy of drawing must show the details of construction, dimensions ( i.e. the length, diameter, height, plate thickness, distance between tyres, total length, gap between the cab and the tank, the rear gap, position and the nos. of the fire extinguishers, location of the fuel tank, the location of the various nozzle connections, height barriers and safety fittings provided etc. The drawing must also show the center of gravity and details calculation of the stability ratio which must be < 1 and necessary noting like registration no., engine no., chassis no., fabricator’s name, applicant’s full postal address with pin code and CCE approval No. of Mounting & Fabrication drawing..

? ? Drawing must also show all nozzle connections, nomenclatures, material of construction, all design data and parameters like design pressure, design temperature, test pressure, corrosion allowance, adequacy of safety valves, excess flow valve, rotogauge, temperature and pressure gauge. ? ? Three copies of Safety certificate under Rule 43 of SMPV(U) Rules 1981 issued by competent person. ? ? Three copies of test and inspection Certificate and certificate of control issued by third party inspecting agency under rule 12(2) in case of new tankers. ? ? Forwarding letter mentioning details of enclosures, Bank Draft No & date etc. Bank draft of Rs . as licence fee/scrutiny fee. The B/D should be drawn on any SUBMISSION OF DOCUMENTS FOR REGRANT OF LICENCE IN FORM IV DUE TO CHANGE IN THE PRIME MOVER / JURISDICTION etc.,

? ? nationalised bank, in favour of Jt. CCE and should be payable at appropriate place as applicable for the concerned licensing authority. For this please see page … of the manual. The Bank Draft should have at least 2 months validity from the date of submission of application for grant of licence.

? ? Application form II duly filled in and signed by the applicant/ authorised employee (in case of company). Typed copy of form II (given in the SMPV(U) Rules, 1981) is acceptable. Please note that no column of the form should be left blank. Inapplicable columns should be filled as NA i.e., not applicable. Full postal address with pin code should be written. No overwriting or major corrections will be accepted. Minor correction should be initialed. ? ? Three copies of drawings (blue print or computerized one without hand correction), each signed by the competent person or the fabricator. Each copy of drawing must show the details of construction, dimensions ( i.e. the length, diameter, height, plate thickness, distance between tyres, total length, gap between the cab and the tank, the rear gap, position and the nos. of the fire extinguishers, location of the fuel tank, the location of the various nozzle connections, height barriers and safety fittings etc. The drawing must also show the center of gravity and details calculation of the stability ratio which must be < 1 and necessary noting like registration no., engine no., chassis

no., fabricator’s name, applicant’s full postal address with pin code and CCE approval No of mounting/fabrication drawing. ? ? The original licence issued by the Explosives Department should be surrendered along with attached drawings. ? ? Attested/Notarized copy of the R.C. Book. ? ? Safety Certificate under Rule 43 issued by the competent person. NOTE :1) In case of change in jurisdiction only in respect of tankers operating under valid licence, it should be considered as amendment only and licence should be issued in lieu of existing licence only after realisation of scrutiny and amendment fee amounting to Rs. 60/-. 2) If the original licence have been claimed to be lost then copy of the FIR together with application should be submitted for issue of duplicate licence along with Demand Draft of Rs. 10/-. The duplicate licence should be issued by the concerned circle from where the original licence was issued earlier. 3) The original licence surrendered by the party should be cancelled in lieu of re-grant of licence due to change of prime mover/jurisdiction. 4) In case of change of prime mover, required licence fee should be realised as the case may be.

Grant of licence (Departmental Action) : The documents submitted by the applicant should be verified and proper scrutiny should be exercised as follows:* If bank draft is found defective or validity expiring shortly should be returned to the party. On receipt of proper bank draft, scrutiny and other checks to be carried out. 1)

FORM II

Verifications include : Name, Registration details, Chassis No. and Engine No. a) The application should be in the name of an individual or a company. Application in joint names should not be accepted. b) The specimen signature of the applicant duly verified/attested by Notary should be appended/pasted in a separate register/Note Sheet in the file for future verifications. c) The applicant’s permanent address should be confirmed and appended on record.

2)

Fees :If bank draft is found defective or validity expiring shortly then the same should be returned to the party. On receipt of proper bank draft, scrutiny and other checks to be carried out. a) Under Rule 11 read with Rule 48 an amount of Rs. 1000/- is required to be paid as licence fee and Rs. 3000/- for a period of 3 years. b) Amendment fee of Rs. 10/- plus differential amount payable for such amendment if any should be realised as per rule 54. c) The licence fees payable in case of renewal of licence should be dealt as per Rule 55 and Sub rule 1 to 8 should be followed scrupulously. d) An amount of Rs. 10/- is payable for issuance of duplicate licence as per rule 61. e) An amount of Rs. 50/- is payable as scrutiny fee (if applicable) as provided under Rule 35.

3)

Certificate of Control issued by the third party inspecting agency : [Rule 12(2)] a) Verification of Dimensions and water capacity with reference to drawing submitted by the party. b) Verification of design temp/pressure with reference to drawing submitted by the party. c) Verification/confirmation of stagewise inspection of vessel by third party inspecting agency. d) Verification of Radiography, Stress relieving, hydrotest pressure, and design pressure . e) Certificate from the fabricator should be verified for identification no. of vessel and other fittings.

f) Reference No. of approval given to the fabrication workshop under SMPV rules and the type of approval for the vessel should be verified. g) The third party inspection agency name should be verified from the list approved by CCE. 4) Safety Certificate issued under Rule 43. a. Verification of fabrication drawing and mounting drawing approval details, vehicle details, and laden weight. b. Safety relief valve shall be set to discharge at an pressure not in excess of 110% of design pressure and shall have a total relieving capacity sufficient to prevent the maximum pressure in the vessel of more than 120% of the design pressure at (Rule 18(2) VII) c. Test of Safety relief valve is valid for a period one year from date of such tests. d. Excess flow valve : Closing rate of flow should be below the rate which is likely to result from fracture of the line it is protecting, calculated under most adverse weather conditions likely to be experienced. e. Hydraulic test of the vessel should be carried out at an interval of 5 years after the date of first test. Validity of such test should be verified from the safety certificate. (Rule 19). This is applicable only for non-toxic/non-corrosive compressed gases and 2 years for toxic/corrosive gases years. f. The safety certificate should clearly indicate that the vehicle For corrosive or toxic gases, the periodic test should be done at an interval of two meets the requirement of SMPV(U) Rules, 1981 and conditions of the licence in form IV. g. The safety certificate should further indicate whether the subject tanker is equipped with emergency safety kit and the person attached to vehicle are well conversant with the operations of such safety kits. h. The name of the competent person should be verified from the list approved by CCE for Rules 18,19, 43 & 44.

5) Three copies of mounting and fabrication drawing should be verified as follows :a. The aforesaid drawings should invariably tally with the original mounting and fabrication drawing of the vehicle and vessel duly approved by CCE. b. Name of the client, and the fabricator should be verified from item no. 1 and item 3 as referred above. c. Maximum permissible gross laden weight and unladen weight should be verified from the R.C. as shown in the drawing. d. Tank fittings, sectional elevation, end view and other details should match with the original fabricator drawing approved by the CCE.

6) Verification of R.C. Book. a. Verification of ownership of the vehicle from the Registration Book. b. Licence should be issued only in the name of the party mentioned in the R.C. Book even if the vessel does not belong to the registered owner and no licence should be granted in joint name. c. The laden and unladen weight should be checked from R.C. Book. d. The Engine no., Chassis No. and other details should be checked from R.C. Book with reference to safety certificated issued under Rule 43. 7) Certificate from Weigh Bridge : a. To confirm the exact unladen weight of the tanker a certificate from weigh bridge duly signed by authorized person of the weigh bridge. b. The unladen weight mentioned in the R.C. or unladen weight of the weigh bridge, which ever is higher should be considered for capacity calculation. c. Maximum permissible laden weight should be taken as indicated in the R.C. Book/Notification issued by Ministry of Surface Transport for capacity calculation. 8) Capacity (payload of the gas) Calculation : a. I) Water capacity of the vessel as indicated in certificate under Rule 43=X II) Liquid density = Y Maximum Capacity allowed in the vessel =0.95.X.Y---------(A) b. Max Lalden weight of the vehicle = M (Laden weight in R.C. Book/vehicle manufacturer specification) Unladen weight as per weighment slip or R.C. Book whichever is higher = N Maximum Permitted carrying capacity of the vehicle = (M-N)------(B) Hence licensed capacity (payload of gas) will be least of A or B. Or M-N > 1 then capacity should be (A)

0.95XY Or M-N < 1 then capacity should be (B) 0.95XY 9. The load distribution of the tanker should be calculated and shown in the documents for application. Note : 1) At no time the calculated/permitted capacity should exceed the maximum permissible carrying capacity certified by the R.T.O./vehicle manufacturer.

2) Filling density of liquefied gases is 95% of reference density at 550C.(for uninsulated non-refrigerated vessels)/operating temperature (for insulated/refrigerated vessels) 3) The maximum permissible quantity/carrying capacity should not exceed 18 MT and 15 MT for compressed gases of flammable and toxic respectively with GVW of 35.2 MT

9) Road worthy certificate : In pursuance of Rule 44(2), the licensee shall ensure that the tanker is at all times road worthy and condition of the tanker is fit to fill, transport and discharge its load safely. The certificate issued in this regard by the competent person is only valid for six months. The validity may be verified accordingly from date of such examination of the vehicle to check that the tanker meets the requirement as per Rule 44 of SMPV Rules 1981. 10) Proforma of pressure vessel manufacturers certificate signed by the fabricator should be verified. The copy of the letter of approval of the fabricator and mounting drawing/fabrication drawing approved by CCE. Should be compared with mounting/fabrication drawing submitted by the party.

Renewal of licence:Renewing Authority: Renewal of licence in Form IV is done by the respective circle office. Note: 1)The licence is renewed for three years at a time. 2) The renewal application should reach the respective circle office 30 days before i.e. on or before 2nd March of the validity year, failing which late fee equivalent to one year licence fee as penalty is required if the renewal application reaches the the renewing authority within 30 days after the validity period i.e. 30th April of that year. B. Various on-line steps adopted for renewal of licence in form II are as under:

? ? Submission of original licence along with the approved drawings and the other required documents by the applicant to the licensing authority for renewal of licence.

? ? Renewal of licence by the Renewing authority. The details of step by step procedure are as under:

Submission of documents by applicant for renewal of licence (Applicants Action) :

Applicant must submit the following documents to the licensing authority for renewal of licence: ? ? Application form II duly filled in and signed by the applicant/ authorized employee. Typed copy of form II (given in the SMPV(U)Rules,1981) is acceptable. Please note that no column of the form should be left blank. Inapplicable columns should be filled as NA i.e., not applicable. Full postal address with pin code should be written. No overwriting or major corrections will be accepted. Minor correction should be initialed. ? ? Attested copy of RC book. ? ? Original licence with approved drawing. Drawing should be kept attached with original licence because it is the part and parcel of licence and licence without drawing is considered as incomplete. ? ? Certificate that emergency kit has been provided. ? ? Certificate required under Rule 18,19&44(2) of SMPV(U) Rules. ? ? Forwarding letter mentioning details of enclosures, Bank Draft No & date etc. Renewal of licence (Departmental Action): The documents submitted by the applicant should be verified and proper scrutiny should be exercised as follows: ? ? If bank draft is found defective or validity expiring shortly should be returned to the party. On receipt of proper bank draft, scrutiny and other checks to be carried out. ? ? The application form submitted by the party should be checked to confirm that the proper mailing address, signature of the party and all other relevant columns have been duly filled in by the applicant. No overwriting

or major corrections will be entertained. Minor correction if any, should be attested by the applicant. ? ? Annual periodical test certificate of S/V to ensure proper working of safety valve. If safety valve is 10 years old then the same may be advice for replacement. ? ? All certificates should be scrutinised to ensure that the certificates and results of test meets the requirements of SMPV(U)Rule 1981. ? ? If thickness is reduced then advised of CCE will be sought whether to derate or condemn the vessel as the case may be. ? ? If any accident or dent of vessel occurs then licensee should be informed to contact third party for examination to ensure that dent are within limit of the code to which vessel has been fabricated. ? ? If repairing is necessary then the party should approach Chief Controller of Explosives as per rule 53 and conditions 12 and 13 of the licence. ? ? If any compliance of inspection report or letter is pending renewal may be withheld till satisfactory compliance is received from the party. ? ? If all are in order then licence is be renewed to validity year as per the licence fee paid by the party.

Addition/Alteration/Amendment of licence:For any addition/alteration amendment in the licence valid under SMPV(U) Rules, in the vehicles like repairs, modification etc. prior approval is to be taken. For that purpose, the licensee has to submit the following documents:i. An application duly filled in and signed in form II for transport of compress gases along with relevant of modification, repairs etc. ii. Test and inspection certificate from Inspectors (for repairs and modification) iii. The original licence sought to be amended together with approved plans/drawings. iv. Licence fee of Rs. 10/- drawn on any nationalized bank in favour of Jt. CCE.

v. Certificate of safety under Rule 43 of SMPV(U) Rules, 1981 in case of change in product and also repairs and modifications. Note : 1) The amendment in the licence can be carried out for any change in registration No., address and any other minor corrections except the change of name of the owner/jurisdiction and the prime mover. 2) For any addition/alteration in the trailor chassis/vessel, or for repairs/other modifications etc. prior approval is necessary from CCE, Nagpur Rule 53. 3) For any change in the product to be transported in the vessel provided for such change of product the vessel fully meets the requirement of design aspect under SMPV(U) Rules, 1981. CHECK LIST DURING INSPECTION

Licence No.

… … … … … ..

Licensee’s Name … … … … Present Sh … … … … … … . Tel. No. … … … … … … … … … … 1. 2.

Date… … .. Place… … . District… … ..

Licence No. marked Yes/No Licence & Plan available. Yes/No Validity of licence … … … .. a) Whether the ownership of the vehicle tallies with the licence. b) Whether the particulars of the vessel mounted on the vehicle are the same as mentioned in the licence and safety certificate. c) Whether safety fittings of the vessel are as per the safety certificate. d) Whether mounting of the vessel on the chassis is proper. e) Whether electrical connections provided in the chassis are through insulating conduits

3.

4.

T T particulars Reg. No. Make & Model Engine No. Chassis No. Regd. Laden weight ULW Trailer or Integrated vehicle Metal plate fixed on vessel as per Rule 16 Yes/No

Name of Manuf. Water Capacity Vessel Id. No. Design pressure Design Temp. Last Hyd. Test date Third party Insp. Agency Whether breathing apparatus/Emergency kit available

5. Yes/No

6.

If yes, Name of manf. of the kit … … … … . Whether driver and attendant trained to use the kit – Yes/No Safety Fittings and other fitments provided : SRV … … … . Nos. make Lot No. Whether over 10 yr. Old Yes/No Last date of test … . SRVs in weld caps or shroud (i)

(ii)

(iii) (iv) (v) (vi) 7. 8. 9. 10. 11. 12. 13. 14. 15.

Sl. No. … … . By … … … …

excess flow Valves : … … … ..nos. make Lot No. … … … . Sl. No. Last test date… … … . By … … … … .. Roto gauge : Make Location Pressure Gauge Make size of dial Temp. indicator Make Fix level gauge Make

Discharge valves enclosed in box with locking arrangement – Yes/No Back of driver’s cabin closed – Yes/No Gap between driver’s cabin and the vessel … … cm. Gap between rear bumper and the rearmost part of the vessel – cm. Whether the chassis is extended beyond 300mm.(in case of fixed chassis) – Yes/No, if yes total length Whether proper marking of the vehicle showing the product which is being carried has been provided – Yes/No Location of cut of switch of not less than 300amps. rating… … … . Guard railing provided Yes/No Height barrier provided Yes/No

16. 17. 18. 19. 20. 21. 22. 23.

Exhaust pipe fitted with Spark Arrestor in case of flammable gases Yes/No Fuel tank guarded with stout metal guard - Yes/No Electric wiring in conduit - Yes/No Fire Extinguishers … … .. Nos. Driver and cleaner trained to use FE – Yes/No Panting and Markings and Hazard classification data as per Motor Vehicle Rules : Highly inflammable/toxic etc. – Yes/No A flexible cable for electrical bonding available – Yes/No Painting & Maintenance of vehicle … . Any other observation Name and designation of Officer

NOTE: 1) The violations/discrepancies noticed during inspection are communicated to the party for complying with the recommendations and submitting compliance report within the stipulated time. In case of serious violations, show cause notice for suspension/cancellation of licence is issued with a notice of 21 days. The party must acknowledge the receipt of the inspection report and submit compliance report within the stipulated time period. Question ? 1. Was it useful in your work activities connected to this department? 2. Are you a frequent visitor to this manual site? 3. Are you a frequent visitor to the offices of this department. 4. What are your specific suggestion to improve it? Give suggestions with reasons. 5. Has this chapter helped you in filing/making proper documents or will your think that you may still face difficulty in filling/making proper forms and documents after reading this chapter? 6. Do you have specific suggestions to make it more user friendly? 7. Do you think of unnecessary element in this chapter which can be avoided/deleted ? 8. Do you have any suggestion (s) for change in Legislation ? Give details with reasons. 9. Give brief details of your organization/yourself through the suggestion form which can be had by clicking the feedback button.

HOME

MODEL DRAWING

LICENCE IN FORM V PROCEDURE TO STORE COMPRESSED GAS AUTO LPG DISPENSING STATION FOR DISPENSING LPG TO MOTOR VEHICLES – Use of LPG as an automotive fuel is the recent development in the country. The Expert Committee constituted by Government of India, Ministry of Petroleum & Natural Gas submitted its detailed report on the subject in 1995 and various Ministries of the Government were to make necessary changes and amendments in their respective acts and rules to allow use of LPG as an automotive fuel. Accordingly, Department of Explosives amended the SMPV(U) Rules, 1981 making provisions for auto LPG dispensing stations under the licence in form V and other necessary requirements. A)

PRIOR APPROVAL : An applicant desiring to install facilities for auto LPG dispensing station should make an application to Chief Controller of Explosives alongwith scrutiny fee of Rs. 100/-, 4 copies of the site plan showing the location, facilities such as roads, buildings and other protected works within 100 mtr. alround, 4 copies of layout plan showing layout of all facilities with their descriptions namely LPG storage tank, tank lorry decanting platform and safety relief valve point, LPG dispenser, LPG pipelines.

NOTE : 1)

2)

3 types of storage vessels i.e. above ground, mounded or under ground are allowed. The requirements for these tanks are different. The above ground tanks have to be provided with fire protection system with sprinklers and fire water storage, fire pump house, fire hydrants etc. whereas in case of mounded or under ground vessels, such fire protection is not require. Only portable fire extinguishers, 70 kg. dry chemical 2 nos. are allowed (refer rule 28). Distances to be maintained within various facilities are given below :-

TABLE - 5 Minimum Safety distances (in meters) between facilities associated with storage and dispensing of liquefied petroleum gas in liquefied Petroleum gas dispensing station as automotive fuel to motor vehicles. To/ From

LPG Storage Vessels

LPG Storage Vessels

Table-3

Fill point of LPG Storage vessel and Centre of LPG TankTruck unloading hard stand LPG Dispenser

9 (aboveground/ mounded vessels exceeding 7500 litres capacity) 6 (aboveground/ mounded vessels not exceeding 7500 litres capacity ) 3 (underground vessel) 9 (aboveground vessels not exceeding 20,000 litres capacity or under-ground/ mounded vessels) 15 (aboveground vessels exceeding 20000 litres capacity) Table-3

Property line Fill point of petroleum class A/B tanks Vent pipe of petroleum class A/B tanks Petroleum

Fill point of LPG Storage vessel and Centre of LPG Tank-Truck unloading hard stand

9 (aboveground/ mounded vessels exceeding 7500 litres capacity) 6 (aboveground/ mounded vessels not exceeding 7500 litres capacity ) 3 (underground vessel)

LPG Dispenser

9 (aboveground vessels not exceeding 20,000 litres capacity or underground/ mounded vessels) 15(aboveground vessels exceeding 20,000 litres capacity)

Property line

Table-3

Petroleum Class A or B service Station licensed in Form XII of Petroleum Rules 1976 Fill point of petroleum class A/B tanks

Vent pipe of petroleum class A/B tanks

Petroleum Class A/B dispensing pump

9

9

9

-6

9

6

6

6

6

--

6

6

6

6

9

6

--

3

4

6

9

6

6

3

--

--

6

9

6

6

4

---

--

6

9

6

6

6

6

6

6

Class A/B dispensing pump

3) 4)

5)

4 copies of drawing showing the installation of the storage vessels, pipes various fittings and control mechanisms. If the dispensing station is proposed in existing retail outlet licence in form XII of Petroleum Rules, 1976 (reference no. of the existing licence if any) is to be submitted. Write-up on design of vessel, anti-corrosive coating, cathodic protection, pipeline, safety specification of dispenser, specification of pumps, safety inter lock and emergency shut down arrangement should also be submitted. The dispenser and the pumps since electrically operated are separately approved by Chief Controller of Explosives after examining specification, type of construction, type of protection as per hazardous area and certification of the equipment by competent testing agency.

DEPARTMENTAL ACTION : If the documents submitted by the applicant are found in order in conformity with the rules and the equipments to be installed are of approved design, approval for the proposal is granted. B)

GRANT OF LICENCE :

After completion of the installation, the applicant is to submit following documents :1) 2) 3)

4) 5)

6)

Application in form I(a). Requisite licence fee by Bank Draft (details given in form III). 4 copies of as built site layout and installation drawings and vessel fabrication drawings. 3 copies of safety certificate under rule 33 from a competent person. 3 copies of test and inspection certificate in respect of pressure vessels from recognized inspector. Copy of approval of tank in respect of dispenser and pumps from Chief Controller of Explosives (if such approval is not obtained in advance, necessary details be submitted along with the application. Copy of licence held for the outlet under the Petroleum Rules. If the site is not covered under the Petroleum Rules, a NOC from the District Authority alongwith site plan endorsed by him is to be submitted.

DEPARTMENTAL ACTION : On scrutiny, if the documents are found in order, licence is granted and sent to Circle/Sub-circle offices of the Department for inspection of the facilities. If the facilities are found in order as per rules and approved drawings, the licence is transmitted to the

licensee. In case of minor deviations, the licensee is asked to comply the same and on receipt of compliance further action towards issue of licence is taken. In case major deviations, the licence is sent back to the Chief Controller of Explosives for cancellation. PRIOR APPROVAL FOR ADDITION/ALTERATION/AMENDMENT ETC. :Same as in form III as page no… ..

Question ? 1. Was it useful in your work activities connected to this department? 2. Are you a frequent visitor to this manual site? 3. Are you a frequent visitor to the offices of this department. 4. What are your specific suggestion to improve it? Give suggestions with reasons. 5. Has this chapter helped you in filing/making proper documents or will your think that you may still face difficulty in filling/making proper forms and documents after reading this chapter? 6. Do you have specific suggestions to make it more user friendly? 7. Do you think of unnecessary element in this chapter which can be avoided/deleted ? 8. Do you have any suggestion (s) for change in Legislation ? Give details with reasons. 9. Give brief details of your organization/yourself through the suggestion form which can be had by clicking the feedback button.

HOME

MODEL DRAWING

Fabrication of pressure vessels

Manufacture of safety fittings for Pressure vessels

Recognition of third party inspecting agency

Recognition of competent person

Repair/modification of pressure vessels

Import of pressure vessels

Feed Back

APPROVED PREMISES UNDER STATIC & MOBILE PRESSURE VESSELS (UNFIRED) RULES, 1981. Under the SMPV(U), Rules, 1981 different types of approvals are granted for different purposes. Approval is granted for fabrication of pressure vessels, manufacture of safety fittings for pressure vessels. Approval is granted for recognition of third party inspecting agency/competent person. Approval is granted for repair/modification of pressure vessels. Approval is also granted for import of pressure vessels.

PROCEDUREFOR GRANT OF APPROVAL/RECOGNITION TO THE APPLICANT (NOT REQUIRING LICENCE) (1) (i)APPROVAL OF SHOP FOR MANUFACTURE OF PRESSURE VESSELS: Any person desiring to manufacture pressure vessels should submit the following documents to Chief Controller of Explosives for approval of the shop :(a) Application in Appendix I in duplicate. (b) Scrutiny fee of Rs.500/NOTE : The required details as per the Appendix I should be given in separate annexures wherever necessary. The details of Bio-data of qualified engineers for manufacture, quality control, testing etc., and particulars of plant, equipments & machineries should be submitted. DEPARTMENTAL ACTION : On scrutiny of the documents, if the proposal appears to be in order, Chief Controller of Explosives refers the case to concerned Circle/Sub-circle office for inspection of the facilities and appraisal of the capabilities of the applicant for manufacturing of pressure vessels. On receipt of the satisfactory report of inspection and appraisal, approval is granted in favour of the applicant. In case, the facilities of the applicant are not adequate or if there are other deficiencies either during scrutiny of initial proposal or during inspection of the site, the same is communicated to the applicant. Question ? 1. Was it useful in your work activities connected to this department? 2. Are you a frequent visitor to this manual site? 3. Are you a frequent visitor to the offices of this department. 4. What are your specific suggestion to improve it? Give suggestions with reasons. 5. Has this chapter helped you in filing/making proper documents or will your think that you may still face difficulty in filling/making proper forms and documents after reading this chapter? 6. Do you have specific suggestions to make it more user friendly? 7. Do you think of unnecessary element in this chapter which can be avoided/deleted ? 8. Do you have any suggestion (s) for change in Legislation ? Give details with reasons. 9. Give brief details of your organization/yourself through the suggestion form which can be had by clicking the feedback button.

MODEL DRAWING

(ii)

APPROVAL OF DESIGN OF PRESSURE VESSELS :-

The pressure vessel shall be manufactured only by company/shop who is approved for such purpose. The design of each type/model of pressure vessel to be manufactured by fabricator should be approved by Chief Controller of Explosives. Documents required to be submitted are as follows :1) 3 copies (static vessel)/7 copies (for mobile vessel) duly vetted by the inspecting agency under whose supervision the vessel is to be manufactured. 2) Design drawings showing the design particulars, code, methods of construction, nozzles etc. 3) The design calculation as per the code duly vetted by the inspecting agency. 4) Safety valve showing sizing calculation. 5) Scrutiny fee of Rs. 500/- for each design of vessel

DEPARTMENTAL ACTION :

On scrutiny of the documents submitted, if the design is found in order, the same is approved. In case of any deficiency, the matter is pointed out to the fabricator/inspector. In case of manufacture of fittings initially a few prototype fittings are allowed to be manufactured and subjected to inspection and testing by the inspecting agency jointly with the field officer of the Department and on receipt of the report of inspection/testing final approval is granted. Question ? 1. Was it useful in your work activities connected to this department? 2. Are you a frequent visitor to this manual site? 3. Are you a frequent visitor to the offices of this department. 4. What are your specific suggestion to improve it? Give suggestions with reasons. 5. Has this chapter helped you in filing/making proper documents or will your think that you may still face difficulty in filling/making proper forms and documents after reading this chapter? 6. Do you have specific suggestions to make it more user friendly? 7. Do you think of unnecessary element in this chapter which can be avoided/deleted ? 8. Do you have any suggestion (s) for change in Legislation ? Give details with reasons.

9. Give brief details of your organization/yourself through the suggestion form which can be had by clicking the feedback button.

MODEL DRAWINGS

iii)

APPROVAL OF MOUNTING DESIGN OF PRESSURE VESSELS (MOBILE PRESSURE VESSELS)

Mounting of the pressure vessel on a vehicle is very important matter. The vessel should be so mounted on a particular vehicle chassis so that both in laden and unladen condition, the stability ratio is less than 1, the load on each axle does not exceed the permitted axle load as per vehicle manufacturers specification and regulations of Ministry of Surface Transport. Further, the vessel should maintain minimum 150 mm. Clearance from the cabin and 75 mm. from the rear bumper. In case of fixed chassis, the vehicle and guard reeling is also to be provided around the vessel. So that in case of its stopping, the vessel is not directly hit. In case the height of the vessel is above the cabin, a height barrier is to be provided on the cabin so as to protect the vehicle while passing the under bridge. For approval of mounting drawing, the following documents are required to be submitted :1) 2) 3) 4)

7 copies of mounting drawing showing make, model of the vehicle. Particulars of vessel to be mounted thereon. Name of the gas to be carried in the vessel. Other details of guard reeling, height barrier, clearances, load distribution, calculation etc. Question ?

1. Was it useful in your work activities connected to this department? 2. Are you a frequent visitor to this manual site? 3. Are you a frequent visitor to the offices of this department. 4. What are your specific suggestion to improve it? Give suggestions with reasons. 5. Has this chapter helped you in filing/making proper documents or will your think that you may still face difficulty in filling/making proper forms and documents after reading this chapter? 6. Do you have specific suggestions to make it more user friendly? 7. Do you think of unnecessary element in this chapter which can be avoided/deleted ? 8. Do you have any suggestion (s) for change in Legislation ? Give details with reasons. 9. Give brief details of your organization/yourself through the suggestion form which can be had by clicking the feedback button.

HOME

MODEL DRAWINGS

PROCEDURE FOR PERIODIC EXAMINATION & TESTING OF PRESSURE VESSELS : For ascertaining the safe status of the pressure vessels they are required to be periodically examined and tested. The pressure vessels meant for toxic/corrosive gases are to be tested at an interval of 2 years and those for other gases to be tested at an interval of 5 years. The periodic testing of smaller vessels for non-toxic/non-flammable gases or for flammable gases should comprise of ultrasonic thickness testing and hydrostatic tests at the designated test pressure as per the fabrication code. Vessels for toxic corrosive gases and large vessels for flammable gases are to be critically examined as follows :Non testing of ultrasonic thickness W.F & P.T, ultrasonic floor detection, dye penetrant test, hardness test and radiography test, in addition to hydro test should be carried out depending on the actual requirement based on defects noticed/anticipated. For hydro spheres additional tests for the supporting columns are also be carried out. Although Ammonia is the toxic gas, horton sphere for ammonia have been allowed by the Govt. to be tested at an interval of 5 years instead of 2 years. NOTE : 1) Testing of Horton spheres have been permitted by Chief Controller of Explosives to be carried out only by the specified inspecting agency who are also recognized as competent person. Other competent persons are not allowed to carry out periodic testing of hydro sphere. 2) Wherever the vessel cannot be safely filled with water, hydro tested for design parameters or where process of water cannot be treated, Chief Controller of Explosives may allow pneumatic test in lieu of hydro testing. In case of defects noticed during periodic inspection or retention of thickness below calculated minimum due to corrosion, the matter should be immediately brought to the notice of the Chief Controller of Explosives for his approval/action for carrying out necessary repairs or derating the vessel as the case may be. Question ? 1. Was it useful in your work activities connected to this department? 2. Are you a frequent visitor to this manual site? 3. Are you a frequent visitor to the offices of this department. 4. What are your specific suggestion to improve it? Give suggestions with reasons. 5. Has this chapter helped you in filing/making proper documents or will your think that you may still face difficulty in filling/making proper forms and documents after reading this chapter? 6. Do you have specific suggestions to make it more user friendly? 7. Do you think of unnecessary element in this chapter which can be avoided/deleted ? 8. Do you have any suggestion (s) for change in Legislation ? Give details with reasons.

9. Give brief details of your organization/yourself through the suggestion form which can be had by clicking the feedback button. HOME

Manufacture of safety fittings for pressure vessels

There are various safety fittings for pressure vessels as under: 1. Safety valve/safety relief valve 2. Excess flow valve 3. Spark Arrester Safety valve/safety relief valve

Excess flow valve

Spark Arrester

RECOGNITION OF COMPETENT PERSON/INSPECTOR : Pressure vessels are very critical equipments and hence manufacture of such pressure vessels are required to be carried out under stage inspection and testing by recognized inspector/inspecting agency. Similarly periodic inspection of pressure vessels and their fittings are also to be carried out by experienced and recognized competent persons. Any person desiring to obtain recognition as inspector or competent person should submit – 1) Application in form ‘A’ of Appendix 3 (for competent person), application in form ‘B’(for inspector) in form ‘C’(competent person). 2) Bio-data of the technical person of the organization giving details of experience in related field and copies of diploma/degree. 3) Scrutiny fee of Rs. 1000/- (for inspector) / Rs. 500/- (for competent person)

NOTE : Details regarding qualification, experience and minimum fees for inspectors and competent persons are given in Appendix 2. DEPARTMENTAL ACTION : If the technical persons of the applicant organization apparently seems to meet the requirements of the rule regarding qualification, experience etc., they are called for an interview to assess their depth of knowledge, requirements of code/standard/procedure etc. If the technical persons of the applicant organization are found to have adequate qualification, knowledge and experience (as assessed above), the organization is granted recognition. The recognition for inspectors in respect of stage inspection and testing of new pressure vessels during its manufacture, repairs etc., the recognition of the competent persons are granted under rule 18 (periodic testing of safety bulbs) rule 19 (for periodic testing of in-service pressure vessels), rule 33 (safety certificate for pressure vessels installation), rule 43 (safety certificate for mobile pressure vessels), rule 44(2) (for periodic thickness certification of mobile pressure vessels) depending on the sphere of experience of applicant organization. For periodic inspection of hydrogen sphere (spherical pressure vessels) only the organization who are recognized both as inspector and competent persons are authorized. Question ? 1. Was it useful in your work activities connected to this department? 2. Are you a frequent visitor to this manual site? 3. Are you a frequent visitor to the offices of this department.

4. What are your specific suggestion to improve it? Give suggestions with reasons. 5. Has this chapter helped you in filing/making proper documents or will your think that you may still face difficulty in filling/making proper forms and documents after reading this chapter? 6. Do you have specific suggestions to make it more user friendly? 7. Do you think of unnecessary element in this chapter which can be avoided/deleted ? 8. Do you have any suggestion (s) for change in Legislation ? Give details with reasons. 9. Give brief details of your organization/yourself through the suggestion form which can be had by clicking the feedback button.

REPAIRS/MODIFICATION OF PRESSURE VESSELS : Repairs/modification of pressure vessels should also be carried out only by approved fabricator under the recognition of the third party inspector. The proposal for repairs/modification of any pressure vessel should contained the following :ii)

iii) iv) v)

The background note for the modification and assessment report of package in case of accident. F.I.R., complete inspection report of the vessel in case of defects during periodic inspection. The procedure for repair and testing duly vetted by the inspector. The modification/repairs drawings showing the details of modification/repair to be carried out. Scrutiny fee of Rs. 500/-

DEPARTMENTAL ACTION : On scrutiny of the documents, if the proposal is found satisfactory, the approval is granted calling for as built drawings and test and inspection certificates carried out during and after the modification/repair for allowing the vessel for fabrication. Question ? 1. Was it useful in your work activities connected to this department? 2. Are you a frequent visitor to this manual site? 3. Are you a frequent visitor to the offices of this department. 4. What are your specific suggestion to improve it? Give suggestions with reasons. 5. Has this chapter helped you in filing/making proper documents or will your think that you may still face difficulty in filling/making proper forms and documents after reading this chapter? 6. Do you have specific suggestions to make it more user friendly? 7. Do you think of unnecessary element in this chapter which can be avoided/deleted ? 8. Do you have any suggestion (s) for change in Legislation ? Give details with reasons. 9. Give brief details of your organization/yourself through the suggestion form which can be had by clicking the feedback button.

IMPORT OF PRESSURE VESSELS : Any person intended to import pressure vessels is required to submit to Chief Controller of Explosives the following documents :(a) (b) (c)

2 copies of test & inspection certificate of the vessel by the manufacturer/third party inspecting agency of the country of origin. Design details of the vessel, its fittings and particulars of specifications of material used for construction. Scrutiny fee of Rs. 500/-.

DEPARTMENTAL ACTION :

On scrutiny of the documents, if the design is found to be a particular standard, international design and safe for the compressed gas in Indian condition permission to import the pressure vessel and approval of the said pressure vessel is granted by Chief Controller of Explosives. Question ? 1. Was it useful in your work activities connected to this department? 2. Are you a frequent visitor to this manual site? 3. Are you a frequent visitor to the offices of this department. 4. What are your specific suggestion to improve it? Give suggestions with reasons. 5. Has this chapter helped you in filing/making proper documents or will your think that you may still face difficulty in filling/making proper forms and documents after reading this chapter? 6. Do you have specific suggestions to make it more user friendly? 7. Do you think of unnecessary element in this chapter which can be avoided/deleted ? 8. Do you have any suggestion (s) for change in Legislation ? Give details with reasons. 9. Give brief details of your organization/yourself through the suggestion form which can be had by clicking the feedback button.